Two-speed transmission having two clutches

ABSTRACT

A two-speed transmission having two clutches includes an electric motor, a middle shaft, a first clutch, a second clutch, a first gear assembly and a second gear assembly. The electric motor includes a spindle. The first clutch and the second clutch are furnished on the middle shaft coaxially. The first gear assembly and the second gear assembly are coupled to the first clutch and the second clutch through a first shaft portion and a second shaft portion of the middle shaft to generate a first gear ratio and a second gear ratio, respectively. When the first clutch is activated to connect with the first shaft portion, the second clutch separates from the second shaft portion, so that the electric motor outputs a first torque corresponding to the first gear ratio through the first gear assembly. Similarly, the electric motor outputs a second torque corresponding to the second gear ratio.

This application claims the benefit of Taiwan application Serial No. 105101238, filed Jan. 15, 2016, the disclosure of which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The disclosure relates in general to a transmission having two clutches, and more particularly to a two-speed transmission for an electric vehicle and capable of providing different torques by switching the speed gears of different gear ratios.

BACKGROUND

As electric vehicle are getting more and more popular, the performance of a transmission is getting more and more important. Most of existing electric vehicles adopt one-speed transmission with a constant gear ratio of 6.4:1˜7.5:1. Under such circumstance, when the vehicle is driving up the slope, the one-speed transmission cannot provide a high torque; and when the vehicle is driving on a flat road, the one-speed transmission cannot provide a high speed due to the restriction of the transmission gear ratio.

Since existing one-speed transmissions cannot be effectively used, many problems will arise. For example, the climbing capability is poor, the start-up is energy consuming, and the efficiency is low. When the vehicle is driving down the slope and the speed is accelerated, the electric motor may be dragged, and to the worse, may even be burnt down.

SUMMARY

The disclosure is directed to a two-speed transmission having two clutches capable of providing two gear ratios to satisfy the driver's different requirements of driving the vehicle at a high torque or driving the vehicle at a high speed respectively. The two-speed transmission having two clutches has the features of high energy utilization rate and strong climbing capacity.

According to one embodiment, a two-speed transmission having two clutches including an electric motor, a middle shaft, a first clutch, a second clutch, a first gear assembly and a second gear assembly is provided. The electric motor includes a spindle. The first clutch and the second clutch are furnished on the middle shaft coaxially. The first gear assembly is coupled to the first clutch through a first shaft portion of the middle shaft to generate a first gear ratio. The second gear assembly is coupled to the second clutch through a second shaft portion of the middle shaft to generate a second gear ratio different from the first gear ratio. When the first clutch is activated to connect with the first shaft portion, the second clutch separates from the second shaft portion, so that the electric motor outputs a first torque corresponding to the first gear ratio through the first gear assembly. When the second clutch is activated to connect with the second shaft portion, the first clutch separates from the first shaft portion, so that the electric motor outputs a second torque corresponding to the second gear ratio through the second gear assembly.

The above and other aspects of the disclosure will become better understood with regard to the following detailed description of the preferred but non-limiting embodiment(s). The following description is made with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B respectively are an appearance diagram of a two-speed transmission for an electric vehicle and a cross-sectional view along a cross-sectional line A-A thereof according to an embodiment of the disclosure.

FIG. 2 is a schematic diagram of a two-speed transmission for an electric vehicle according to an embodiment of the disclosure.

FIGS. 3 and 4 respectively are an internal structural diagram of a two-speed transmission for an electric vehicle and a simplified reference diagram thereof according to an embodiment of the disclosure.

FIGS. 5A-5C respectively are operation diagrams of a two-speed transmission for an electric vehicle according to an embodiment of the disclosure.

In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawing.

DETAILED DESCRIPTION

In an embodiment of the disclosure, the transmission has two switchable clutches. As one clutch connects with the middle shaft and the other clutch separates from the middle shaft, different gear ratios can be provided to meet different requirements of providing a high torque when the vehicle is driving up the slope and achieving a high rotation speed when the vehicle is driving on a flat road. Thus, the climbing capability can be improved and the energy utilization rate can be increased.

In an embodiment, two gears with different gear ratios are respectively installed on the differential and are controlled by respective clutches. When the first clutch connects with the first shaft portion of the middle shaft, the second clutch separates from the second shaft portion of the middle shaft. Meanwhile, the rotor of the electric motor drives the spindle and the middle shaft to rotate and output a first torque corresponding to the gear ratio of the first gear assembly through the first gear assembly. Then, the first gear assembly is meshed with the differential through the output shaft gear to transfer the first torque to the power output shaft of the vehicle.

Besides, when the first clutch separates from the first shaft portion of the middle shaft, the second clutch connects with the second shaft portion of the middle shaft. Meanwhile, the rotor of the electric motor drives the spindle and the middle shaft to rotate and output a second torque corresponding to the gear ratio of the second gear assembly through the second gear assembly. Then, the second gear assembly is meshed with the differential through the output shaft gear to transfer the second torque to the power output shaft of the vehicle.

The first torque is a high torque corresponding to the first gear assembly with a high gear ratio under which the vehicle can achieve a low rotation speed but a high torque. The high gear ratio is applicable to the vehicle starting up or driving up or down the slope. The second torque is a low torque corresponding to the second gear assembly with a low gear ratio. Under the low gear ratio, the vehicle can achieve a high rotation speed but a low torque. The low gear ratio is applicable to the vehicle driving on a flat road.

A number of embodiments are disclosed below for elaborating the disclosure. However, the embodiments of the disclosure are for detailed descriptions only, not for limiting the scope of protection of the disclosure.

Refer to FIGS. 1˜4. FIGS. 1A and 1B respectively are an appearance diagram of a two-speed transmission 100 for an electric vehicle and a cross-sectional view along a cross-sectional line A-A thereof according to an embodiment of the disclosure. FIG. 2 is a schematic diagram of a two-speed transmission 100 for an electric vehicle according to an embodiment of the disclosure. FIGS. 3 and 4 respectively are an internal structural diagram and a simplified reference diagram of a two-speed transmission 100 for an electric vehicle according to an embodiment of the disclosure.

As indicated in FIGS. 1A, 1B and 2, a two-speed transmission 100 for an electric vehicle includes an electric motor 110, a middle shaft 115, a first gear assembly 120, a first clutch 125, a second gear assembly 130 and a second clutch 135. The electric motor 110 includes a stator 111, a rotor 112 and a spindle 113. The stator 111 is fixed on the housing of the electric motor 110. The center of the rotor 112 connects with the spindle 113 and drives the spindle 113 to rotate. The spindle 113 can output the power of the electric motor 110 to a driving mechanism, such as the differential 118T and the power output shaft 117 of a vehicle. In an embodiment, the electronic control unit (ECU) detects vehicle speed and road conditions by using an external sensor. The ECU can switch the two-speed transmission 100 for an electric vehicle between a first shift mode and a second shift mode to adjust the gear ratio of the transmission, such that the power outputted by the electric motor 110 can meet the requirement of providing a high torque or achieving a high rotation speed.

As indicated in FIG. 1A, each of the spindle 113, the middle shaft 115 and the power output shaft 117 has two bearings B, such as ball bearings, through which the spindle 113, the middle shaft 115 and the power output shaft 117 can be firmly installed within the body of the two-speed transmission 100 for an electric vehicle.

The first gear assembly 120 includes a first main gear 121 and a first counter gear 122, wherein the first main gear 121 is furnished on the first shaft portion 115A of the middle shaft 115 and couples to the first clutch 125, and the first counter gear 122 is furnished on the differential 118T. The first gear assembly 120 can generate a first gear ratio.

The second gear assembly 130 includes a second main gear 131 and a second counter gear 132, wherein the second main gear 131 is furnished on the second shaft portion 115B of the middle shaft 115, and the second counter gear 132 is furnished on the differential 118T and couples to the second clutch 135. The second gear assembly 130 can generate a second gear ratio different from the first gear ratio. In an embodiment, a bearing 119, such as a ball bearing is furnished between the first shaft portion 115A and the second shaft portion 115B of the middle shaft 115, such that the first shaft portion 115A and the second shaft portion 115B can be rotated coaxially. Additionally, the diameter of the second shaft portion 115B is larger than the diameter of the first shaft portion 115A, such that the second shaft portion 115B can be mounted on the first shaft portion 115A, and the actual length of the middle shaft 115 can be reduced. However, the disclosure is not limited thereto, and the second shaft portion 115B can be furnished in a different way.

Moreover, the spindle gear 114 is furnished on the spindle 113, and the middle shaft gear 116 is furnished on the clutch. The spindle gear 114 is meshed with the middle shaft gear 116 to transfer the power of the electric motor 110.

The first gear assembly 120 outputs the power of the electric motor 110 as a first torque, and drives the differential 118T to rotate and transfer the first torque to the power output shaft 117 of the vehicle. The second gear assembly 130 outputs the power of the electric motor 110 as a second torque, and drives the differential 118T to rotate and transfer the second torque to the power output shaft 117 of the vehicle. In another embodiment, the middle shaft gear 116 and the spindle gear 111 are coupled by a belt or other moving parts to output the power.

As disclosed above, two gear assemblies with different gear ratios are used in conjunction with a clutch controller to switch the gears of different gear ratios and provide different torques to the power output shaft 117 of the vehicle, such that the different requirements of high torque or high speed can be satisfied. The gear ratio is a ratio of the number of teeth of the output gear to the number of teeth of the input gear. The first gear ratio, such as between 6˜7, is applicable to the situation when a high rotation speed is required. The second gear ratio, such as 11˜12, is applicable to the situation when a high torque is required. The definition of the first gear ratio and the definition of the second gear ration are exchangeable, and the disclosure does not have specific restrictions to the gear ratio.

Refer to FIGS. 3 and 4. The middle shaft gear 116 is furnished on a common housing 124 of the first clutch 125 and the second clutch 135, wherein the first clutch 125 and the second clutch 135 can be a set of friction-plate clutches. The first clutch 125 includes a plurality of first static friction plates 126 furnished on the clutch centering sleeve 128 and a plurality of first dynamic friction plates 127 staggered with the first static friction plates 126 and neighboring with the first static friction plates 126 to each other. The second clutch 135 includes a plurality of second static friction plates 136 furnished on the clutch centering sleeve 138 and a plurality of second dynamic friction plates 137 staggered with the second static friction plates 136 and neighboring with the second static friction plates 136 to each other.

The first dynamic friction plates 127 are furnished on the inner-wall of the common housing 124, and the first dynamic friction plates 127 match the inner spline TS1 furnished on the common housing 124 and extended in an axial direction of the middle shaft 115, such that the first dynamic friction plates 127 can move on the inner spline TS1 along the axial direction. The first dynamic friction plates 127 rotate around the middle shaft 115 through the rotation of the common housing 124. The first static friction plates 126 match the outer spline TS2 furnished on the clutch centering sleeve 128 and extended along an axial direction of the middle shaft 115, such that the first static friction plates 126 can move on the outer spline TS2 along the axial direction. A first pressure disc 129 is furnished on the clutch centering sleeve 128. The first pressure disc 129 can be driven by the hydraulic circuit 140 to move along an axial direction of the middle shaft 115 (the axial direction is represented by arrow signs) and push the first static friction plates 126 to tightly connect with the first dynamic friction plates 127.

FIGS. 5A˜5C respectively are operation diagrams of a two-speed transmission for an electric vehicle according to an embodiment of the disclosure. Refer to FIG. 5A. When the first piston P1 is pushed on by the hydraulic circuit 140, the first pressure disc 129 furnished on the clutch centering sleeve 128 is activated by the first piston P1 to tightly press the first static friction plates 126 and the first dynamic friction plates 127, such that the first static friction plates 126 and the first dynamic friction plates 127 tightly connect with each other. The first static friction plates 126 are furnished on the clutch centering sleeve 128 which is further coupled to the first shaft portion 115A of the middle shaft 115. After the first static friction plates 126 and the first dynamic friction plates 127 are tightly pressed by the first pressure disc 129, the power outputted from the electric motor 110 (the rotor 112) is transferred to the first gear assembly 120 through the first shaft portion 115A of the middle shaft 115 connecting with the first clutch 125 and then converted into a first torque, wherein the first torque corresponds to the gear ratio of the first gear assembly 120. Then, the first torque is further outputted to the differential 118T and the power output shaft 117 through a power transmission path represented by arrow signs as indicated in FIG. 5A. Conversely, after the first pressure disc 129 is released and returns to the original position, the first static friction plates 126 and the first dynamic friction plates 127 are not connected with each other, therefore the power outputted from the electric motor 110 will not be transferred to the middle shaft 115.

Besides, the second dynamic friction plates 137 are furnished on the inner-wall of the common housing 124, and the second dynamic friction plates 137 match the inner spline TS3 furnished on the common housing 124 and extended along an axial direction of the middle shaft 115, such that the second dynamic friction plates 137 can move on the inner spline TS3 along the axial direction. The second dynamic friction plates 137 synchronically rotate around the middle shaft 115 through the rotation of the common housing 124. Moreover, the second static friction plates 136 match the outer spline TS4 furnished on the clutch centering sleeve 138 and extended along an axial direction of the middle shaft 115, such that the second static friction plates 136 can move on the outer spline TS4 along the axial direction. A second pressure disc 139 is furnished on the clutch centering sleeve 138. The second pressure disc 139 can be driven by the hydraulic circuit 140 to move along an axial direction of the middle shaft 115 and push the first static friction plates 126 to tightly connect with the first dynamic friction plates 127.

Refer to FIG. 5B. When the second piston P2 is pushed on by the hydraulic circuit 140, the second pressure disc 139 furnished on the clutch centering sleeve 138 is activated by the second piston P2 to tightly press the second static friction plates 136 and the second dynamic friction plates 137, such that the second static friction plates 136 and the second dynamic friction plates 137 tightly connect with each other. The second static friction plates 136 are furnished on the clutch centering sleeve 138, which is further coupled to the second shaft portion 115B of the middle shaft 115. After the second static friction plates 136 and the second dynamic friction plates 137 are tightly pressed by the second pressure disc 139, the power outputted from the electric motor 110 (the rotor 112) is transferred to the second gear assembly 130 through the second shaft portion 115B of the middle shaft 115 connecting with the second clutch 135 and then converted into a second torque, wherein the second torque corresponds to the gear ratio of the second gear assembly 130. Then, the second torque is further outputted to the differential 118T and the power output shaft 117 through the power transmission path indicated by the arrows of FIG. 5B. Conversely, after the second pressure disc 139 is released, the second static friction plates 136 and the second dynamic friction plates 137 are not connected with each other, therefore the power outputted from the electric motor 110 will not be transferred to the middle shaft 115.

Refer to FIG. 5C. When the first clutch 125 and the second clutch 135 are not driven by the hydraulic circuit 140, the spindle 113 cannot output the power to the middle shaft 115. Under such circumstance, the rotor 112 of the electric motor 110 is idled and no torque is outputted to the middle shaft 115, and the electric motor 110 of the electric vehicle maintains at idle speed.

As disclosed above, the clutch controller controls the first clutch 125 and the second clutch 135 by using the first piston P1, the second piston P2 and the switching of the on/off state of the hydraulic circuit 140. That is, when the first static friction plates 126 and the first dynamic friction plates 127 of the first clutch 125 are pressed tightly to connect with each other, the second static friction plates 136 and the second dynamic friction plates 137 of the second clutch 135 separate from each other. Conversely, when the first static friction plates 126 and the first dynamic friction plates 127 of the first clutch 125 separate from each other, the second static friction plates 136 and the second dynamic friction plates 137 of the second clutch 135 are pressed tightly to connect with each other. Since the shifting operation of the clutches 125 and 135 is easy and reliable, the neutral gear, which may cause intermittent output of torque and make the vehicle jittering, can be avoided during the process of shifting gears, and driving comfort will thus be greatly improved.

Each of the two ports V1 and V2 of the hydraulic circuit 140 has a control valve (not illustrated) for controlling the pressure and flow of the ports V1 and V2 so as to adjust the internal pressure of the hydraulic cylinder. Given that the two ports V1 and V2 can share one hydraulic cylinder, the inlet direction and the outlet direction can be switched, and the first piston P1 and the second piston P2 can be integrated in one piece and furnished within the hydraulic cylinder, one hydraulic circuit 140 would do, and the structure of the transmission can be simplified. Since the hydraulic circuit 140 can be connected to one single pump through a pump switch and can further drive the first clutch 125 and the second clutch 135 by using the one single pump, the hydraulic circuit 140 has a simplified structure, a smaller volume and a lighter weight.

The two-speed transmission for an electric vehicle disclosed in above embodiments of the disclosure is capable of providing two gear ratios to satisfy the driver's different requirements of driving the vehicle at a high torque or driving the vehicle at a high speed respectively. The two-speed transmission having two clutches has the features of high energy utilization rate and strong climbing capacity. Additionally, the two-speed transmission of the disclosure, having a compact and robust structure, is light and small and easy to assemble, enhances the power of the electric vehicle and is beneficiary to the standardization and use of the electric vehicle.

It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed embodiments. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents. 

What is claimed is:
 1. A two-speed transmission having two clutches, comprising: an electric motor, comprising a spindle; a middle shaft; a first clutch and a second clutch coaxially furnished on the middle shaft; a first gear assembly coupled to the first clutch through a first shaft portion of the middle shaft to generate a first gear ratio; and a second gear assembly coupled to the second clutch through a second shaft portion of the middle shaft to generate a second gear ratio that is different from the first gear ratio; wherein, when the first clutch is activated to connect with the first shaft portion, the second clutch separates from the second shaft portion, so that the electric motor outputs a first torque corresponding to the first gear ratio through the first gear assembly; when the second clutch is activated to connect with the second shaft portion, the first clutch separates from the first shaft portion, so that the electric motor outputs a second torque corresponding to the second gear ratio through the second gear assembly.
 2. The two-speed transmission according to claim 1, wherein when the first clutch and the second clutch are not connected to the first shaft portion and the second shaft portion of the middle shaft respectively, a rotor within the electric motor is idled and no torque is outputted to the middle shaft from the electric motor.
 3. The two-speed transmission according to claim 1, wherein the first gear assembly comprises a first main gear furnished on the first shaft portion and a first counter gear meshed with the first main gear.
 4. The two-speed transmission according to claim 3, wherein the second gear assembly comprises a second main gear furnished on the second shaft portion and a second counter gear meshed with the second main gear.
 5. The two-speed transmission according to claim 4, further comprising a differential and a power output shaft, wherein the first gear assembly or the second gear assembly drives the differential to rotate and transfer the first torque or the second torque to the power output shaft.
 6. The two-speed transmission according to claim 1, further comprising a middle shaft gear, wherein the middle shaft gear is furnished on a clutch common housing, and the middle shaft gear together with the first clutch and the second clutch are coaxially furnished on the middle shaft.
 7. The two-speed transmission according to claim 6, further comprising a spindle gear, wherein the spindle gear is meshed with the middle shaft gear.
 8. The two-speed transmission according to claim 1, wherein the first clutch comprises a plurality of first static friction plates furnished on a clutch centering sleeve and a plurality of first dynamic friction plates staggered with the first static friction plates and neighboring with the first static friction plates to each other.
 9. The two-speed transmission according to claim 8, wherein the first dynamic friction plates are furnished on an inner-wall of a clutch common housing and synchronically rotate around the middle shaft through the rotation of the first gear assembly.
 10. The two-speed transmission according to claim 9, wherein the first dynamic friction plates match an inner spline furnished on the clutch common housing and extended along an axial direction of the middle shaft, such that the first dynamic friction plates is movable on the inner spline along the axial direction.
 11. The two-speed transmission according to claim 8, wherein the first static friction plates match an outer spline furnished on the clutch centering sleeve and extended along an axial direction of the middle shaft, such that the first static friction plates is movable on the outer spline along the axial direction.
 12. The two-speed transmission according to claim 8, wherein a first pressure disc is furnished on the clutch centering sleeve, and is activated to move along an axial direction of the middle shaft and tightly press the first static friction plates and the first dynamic friction plates, such that the first static friction plates and the first dynamic friction plates tightly connect with each other.
 13. The two-speed transmission according to claim 12, wherein the first pressure disc is driven in a hydraulic manner.
 14. The two-speed transmission according to claim 1, wherein the second clutch comprises a plurality of second static friction plates furnished on a clutch centering sleeve and a plurality of second dynamic friction plates staggered with the second static friction plates and neighboring with the second static friction plates to each other.
 15. The two-speed transmission according to claim 14, wherein the second dynamic friction plates are furnished on an inner-wall of a clutch common housing and synchronically rotate around the middle shaft through the rotation of the second gear assembly.
 16. The two-speed transmission according to claim 15, wherein the second dynamic friction plates match an inner spline furnished on the clutch common housing along an axial direction of the middle shaft, such that the second dynamic friction plates is movable on the inner spline along the axial direction.
 17. The two-speed transmission according to claim 14, wherein the second static friction plates match an outer spline furnished on the clutch centering sleeve and extended along an axial direction of the middle shaft, such that the second static friction plates is movable on the outer spline along the axial direction.
 18. The two-speed transmission according to claim 14, wherein a second pressure disc is furnished on the clutch centering sleeve and is activated to move along an axial direction of the middle shaft and tightly press the second static friction plates and the second dynamic friction plates, such that the second static friction plates and the second dynamic friction plates tightly connect with each other.
 19. The two-speed transmission according to claim 18, wherein the second pressure disc is driven in a hydraulic manner.
 20. The two-speed transmission according to claim 1, wherein the first shaft portion and the second shaft portion of the middle shaft are coaxial, and a bearing is furnished between the first shaft portion and the second shaft portion. 